Quality Improvement Methodologies

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    Research paper476 Copyright by International OCSCO World Press. All rights reserved. 2010

    VOLUME 43

    ISSUE 1

    November

    2010

    of Achievements in Materials

    and Manufacturing Engineering

    of Achievements in Materials

    and Manufacturing Engineering

    Quality Improvement Methodologies

    PDCA Cycle, RADAR Matrix, DMAIC

    and DFSS

    M. Sokovic a,*, D. Pavletic b, K. Kern Pipan c

    a

    Faculty of Mechanical Engineering, University of Ljubljana,Askerceva 6, SI-1000 Ljubljana, SloveniabFaculty of Engineering, University of Rijeka, Vukovarska 58, 51000 Rijeka, CroatiacMinistry of Higher Education, Science and Technology, Metrology Institute of the

    Republic of Slovenia (MIRS), Grudnovo nabrezje 17, SI-1000, Ljubljana, Slovenia

    * Corresponding author: E-mail address: [email protected]

    Received 07.09.2010; published in revised form 01.11.2010

    Industrial management and organisation

    ABSTRACT

    Purpose:of this paper is to introduce the reader to the characteristics of PDCA tool and Six Sigma (DMAIC,

    DFSS) techniques and EFQM Excellence Model (RADAR matrix), which are possible to use for the continuous

    quality improvement of products, processes and services in organizations.

    Design/methodology/approach:We compared the main characteristics of the presented methodologies aiming

    to show the main prerequisites, differences, strengths and limits in their application.

    Findings:Depending on the purpose every organization will have to find a proper way and a combination of

    methodologies in its implementation process. The PDCA cycle is a well known fundamental concept of continuous-

    improvement processes, RADAR matrix provides a structured approach assessing the organizational performance,

    DMAIC is a systematic, and fact based approach providing framework of results-oriented project management,

    DFSS is a systematic approach to new products or processes design focusing on prevent activities.

    Research limitations/implications: This paper provides general information and observations on four

    presented methodologies. Further research could be done towards more detailed study of characteristics and

    positive effects of these methodologies.

    Practical implications: The paper presents condensed presentation of main characteristics, strengths and

    limitations of presented methodologies. Our findings could be used as solid information for management

    decisions about the introduction of various quality programmes.

    Originality/value:We compared four methodologies and showed their main characteristics and differences.

    We showed that some methodologies are more simple and therefore easily to understand and introduce (e.g.

    PDCA cycle). On the contrary Six Sigma and EFQM Excellence model are more complex and demanding

    methodologies and therefore need more time and resources for their proper implementation.

    Keywords:Quality continuous improvement; PDCA Cycle; EFQM Excellence Model; RADAR Matrix; Six Sigma

    Referenceto this paper should be given in the following way:

    M. Sokovic, D. Pavletic, K. Kern Pipan, Quality Improvement Methodologies PDCA Cycle, RADAR Matrix,

    DMAIC and DFSS, Journal of Achievements in Materials and Manufacturing Engineering 43/1 (2010) 476-483.

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    Industrial management and organisation

    1. Introduction

    Different organizations use different methodologies,

    approaches and tools for implementing a quality management and

    programmes for continuous quality improvement. The programme

    is likely to have a different name or label, such as TQM (TotalQuality Management), Six Sigma, BPR (Business Process Re-

    engineering), Operational Excellence or Business Excellence.

    Regardless of the methodology, approach, tool or the name of the

    continuous improvement programmes, each organization will

    certainly need to use a proper selection and combination of

    different approaches, tools and techniques in its implementation

    process. Most of these tools, approaches and techniques are used

    worldwide and simple to understand and can be used by a large

    number of people of the company, e.g.PDCA cycle or Deming's

    circle. However, some techniques in this area are more complex

    and demanding, e.g. Six Sigma, Lean Sigma, Design for Six

    Sigma or EFQM excellence model. Specialists for specific

    problem-solving applications and implementation use these

    advanced techniques and methodologies. It is very important thattools, approaches and techniques should be selected for the

    appropriate team and applied correctly to the appropriate process.

    The successful implementation of approaches, tools and

    techniques depends on their understanding, knowledge and proper

    application in organizational processes.

    2. The PDCA cycle

    2.1. Definition

    In a central process, the actual results of an action are

    compared with a target or a set point. The difference between the

    two is then mentioned and corrective measures are adopted if the

    disparity becomes large. The repeated and continuous nature of

    continuous improvement follows this usual definition of control

    and is represented by the PDCA (Plan-Do-Check-Act) cycle[1].

    This is also referred to as the Deming circle, named after W.

    E. Deming. Another variation of PDCA is PDSA (Plan, Do,

    Study, Act) [2].

    Act

    Managing Nonconformity

    Improvement

    ISO 9001 Certification

    Cultural and Organizational Aspects

    Total Quality Management

    Environmental Management Systems

    Management System Integration

    Plan

    The Quality Concept and Objectives

    Statutory Considerations

    Product Liability and Product Safety

    Training for Quality

    The Control of Design

    Check

    An Introduction to Statistics

    Control Charts

    Inspection

    Functional Testing Inspection and Measurement Equipment

    Metrology

    Quality Audits and Reviews

    Quality- and Safety-related Cost

    Benchmarking

    Do

    Procurement

    Just-in-Time Supplies

    Process Capability

    Product Reliability Materials Handling

    Servicing

    Service Quality

    Documentations and Records

    Controlling Changes

    Standards, Standardization, Conformity and

    Compatibility

    Fig. 1. PDCA cycle

    1. Introduction

    2. The PDCA cycle

    2.1. Definition

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    Journal of Achievements in Materials and Manufacturing Engineering

    M. Sokovic, D. Pavletic, K. Kern Pipan

    Volume 43 Issue 1 November 2010

    2.2. Application

    The application of the PDCA cycle has been found more

    effective than adopting the right first timeapproach. Using of

    the PDCA cycle means continuously looking for better methods

    of improvement. The PDCA cycle is effective in both doing a joband managing a programme. The PDCA cycle enables two types

    of corrective action temporary and permanent.

    The temporary action is aimed at results by practically

    tackling and fixing the problem. Thepermanent corrective action,

    on the other hand, consists of investigation and eliminating the

    root causes and thus targets the sustainability of the improved

    process.

    The aspects of the PDCA cycle were applied to internal

    quality-assurance procedures: What are we trying to accomplish?

    How will we know that a change is an improvement?

    What changes can we make to improve?

    Figure 1 shows the PDCA cycle in detail [3,4]. In the Do

    stage or implementation stage it is possible to involve a mini-

    PDCA cycle (Fig. 2) until the issues of implementation are

    resolved [5].

    Fig. 2. Advanced PDCA cycle [5]

    The PDCA cycle is more than just a tool; it is a concept of

    continuous improvement processes (Fig. 3) embedded in the

    organizations culture. The most important aspect ofPDCA lies inthe actstage after the completion of a project when the cycle

    starts again for the further improvement.

    Fig. 3. PDCA cycle in continuous improvement process

    The PDCA cycle is also possible to use within the Kaizen

    concept, Figure 4. In this case we are talking about the SDCA -

    PDCA cycle [6].

    While Deming's PDCA cycle has been extensively used in the

    development and deployment of quality policies, DMAIC (Six

    Sigma) and DMADV (DFSS) have added the rigour of project

    life-cycle (PLC) to the implementation and close-out of Six

    Sigma projects, RADAR (EFQM Excellence model) has been

    used for assessment of organizational performance. Figure 5shows the relationship between PDCA cycle, DMAIC, DMADV,

    and typical project-life cycle and RADAR matrix [1,2].

    3. EFQM model

    3.1. Definition

    EFQM Excellence Model is a non-prescriptive framework

    that recognizes that sustained excellence can be achieved by using

    different approaches [7-9]. Excellence Model is based on the idea

    that customer satisfaction, employee and positive impact on

    society together contribute to excellent business results [10].

    Organizations through the cyclical process of self-assessmentobtain a powerful tool to further enhance of continuous learning,

    improvement and innovative thinking. Philosophy of Excellence

    model is that the organization achieves exceptional key results of

    performance with integration of employees and process

    improvement [11]. EFQM Excellence Model in its 15 years of

    existence proved its credibility in relation to the purposes for

    which it was founded: to recognize excellence (this is the highest

    organizational level of quality). In general the model effects like

    "standard" for identification of organizational quality and enables

    comparisons between different organizations [12]. The EFQM

    Excellence Model is a practical, non-prescriptive framework that

    enables organisations to:

    Assess where they are on the path to excellence; helping them

    to understand their key strengths and potential gaps in relationto their stated vision and mission.

    Provide a common vocabulary and way of thinking about the

    organisation that facilitates the effective communication of

    ideas, both within and outside the organisation.

    Integrate existing and planned initiatives, removing duplication

    and identifying gaps.

    Provide a basic structure for the organisations management

    system [9].

    Fig. 4. SDCA PDCA cycles for quality improvement in the

    Kaizen concept

    2.2. Application

    3. Conclusions

    3.1. Definition

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    Quality Improvement Methodologies PDCA Cycle, RADAR Matrix, DMAIC and DFSS

    Fig. 5. The PDCA cycle vs. DMAIC (Six Sigma), DMADV

    (DFSS), the Project-Life Cycle (PLC) and RADAR (Excellence

    model

    3.2. Application

    The EFQM Excellence Model belongs to the integral

    management tools where all important organisational areas can be

    analysed against its targets (results) and resources (enablers).

    Model provides a cause-and-effect link between the approaches

    used by the organisation to reach the set goals, and the actual

    results achieved. The model makes it possible to establish a

    rounded system for measuringprogress in the performance of allkey areas of activity of the organisation using the RADAR matrix

    methodology (0 to 1000 points) [13].

    EFQM excellence model [9] (Fig. 6) consists of nine criteria,

    five of them are enablers (Leadership, Strategy, People,

    Partnerships & Resources and Processes, Products & Services) and

    four of them are results (Results criteria; Customer Results, People

    Results, Society Results and Key Results). The left side of the

    Model, "Enablers", and the right side, "Results", directly follow

    each other and are in direct cause-effect relationship, and together

    they make a whole. The Results reflect successfully implemented

    approaches at the "Enablers" side. Learning, creativity and

    innovation are the driving forces of development in an

    organization. Within this framework the RADAR matrix lying at

    the heart of the model should be considered [9].

    However essential part in using model can be found in

    internal self-assessment of organization. Experiences of different

    organizations show that self-assessment effects positively on team

    work, organizational culture, dialogue and communication. The

    regular self-assessments systematically encourage the

    organizations and its people to on-going learning, continuous

    improvement and innovation. As a summary of the application of

    the EFQM excellence we can conclude that model is a long-term,

    strategic tool where all organizational aspects and areas can be

    monitored, assessed and improved. Therefore it cannot be used as

    a tool for day-to-day business, since its positive effects can be

    seen in long term. Due of its complexity it should be introduced

    properly with strong support and commitment of top-management

    and appropriate training of the people included.

    Fig.6. EFQM Excellence model (version 2010)

    4. RADAR Matrix

    4.1. Definition

    RADAR (Results, Approach, Deploy, Assess and Refine)provides a structured approach to question the performance of an

    organisation; it is an essential part of a companys programme using

    EFQM excellence model. RADAR is an acronym for five

    interconnected phases: results, approach, deploy, assess and refine.

    The simplified definitions of each phase are [9]:

    Determine the Results it is aiming to achieve as part of its

    strategy.

    Plan and develop an integrated set of sound Approaches to

    deliver the required results both now and in the future.

    Deploy the approaches in a systematic way to ensure

    implementation. Assess and Refine the deployed approaches based on

    monitoring and analysis of the results achieved and ongoing

    learning activities.

    RADAR matrix support all nine criteria of EFQM excellence

    model with enabler matrix which is used to support the analysis of

    the approaches within the five enabler criteria and the results

    matrix which is used to support the analysis of the results within

    the four results criteria.

    4.2. Application

    The tool of RADAR Matrix is used for assessment of

    organizational performance and applied within the EFQM

    excellence model. As such, it is an integral part of the excellence

    model methodology. RADAR provides a structured approach to

    question the performance of an organisation.

    The RADAR logic provides a structured approach to questionthe performance of an organisation using EFQM excellence

    model. It also supports the scoring mechanism behind the

    European Excellence Award and other recognition or assessment

    schemes and can help to lead change and manage improvementprojects in an organisation. Today more than 26 national and

    excellence awards are established in countries of European Union.

    3.2. Application

    4. RADAR Matrix

    4.1. Definition

    4.2. Application

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    M. Sokovic, D. Pavletic, K. Kern Pipan

    Volume 43 Issue 1 November 2010

    With the support of RADAR logic it is possible to make arobust assessment of the degree of excellence of any organisation

    [9]. The criteria for a particular phase of RADAR are defined and

    organization (or its part) is reviewed through all four phases toassess organizational performance in a systematic way, Figure 7 [9,14].

    We can find synergy of the RADAR matrix with the Demingcycle. Every approach, which is being introduced into an

    organisation, can be checked against the PDCA cycle, as follows:1. In the Plan phase check that the approaches used are sound,

    focused on the all stakeholders the needs and integrated withother appropriate approaches.

    2. In the Do phase check that the approaches are implemented

    systematically in all relevant areas throughout theorganisation to the full extent. Check that the appropriate

    tools exist to measure the effectiveness and the planned

    benefits of the implemented approaches.3. In the Check and Act phases check that the efficiency of the

    approaches and their deployment are regularly measured; that

    there are enough learning activities; that benchmarking isperformed, e.g. in sector / best in class. Check that the

    improvement of approaches is based on learning activity and

    performance measurements [15].As a summary of the application of the RADAR matrix

    methodology, if you cannot measure your process, you cannot

    define its level of performance and you cannot improve it. Thatmeans if you cannot establish the systematic integrated

    monitoring system on your approaches you are not able to utilize

    RADAR in your organization. Therefore, appropriate systematicmonitoring and assessing system is the basis for implementation

    of continuous improvements in the organization.

    5. DMAIC

    5.1 Definition

    DMAIC (Define, Measure, Analyse, Improve, and

    Control)refers to a data-driven life-cycle approach to Six Sigma

    projects for improving process; it is an essential part of acompany's Six Sigma programme. DMAIC is anacronym for fiveinterconnected phases: define measure, analyse, improve andcontrol. The simplified definitions of each phase (Fig. 8) are [1]:

    Define by identifying, prioritizing and selecting the right

    project,

    Measure key process characteristic, the scope of parametersand their performances,

    Analyseby identifying key causes and process determinants,

    Improve by changing the process and optimizing

    performance,

    Controlby sustaining the gain.

    Fig. 7.The RADAR matrix cycle as a methodology of EFQM Excellence model

    5. DMAIC

    5.1. Definition

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    Fig. 8. The DMAIC cycle as a methodology of Six Sigma

    5.2 Application

    The tools of Six Sigma and operational excellence are most

    often applied within the framework of DMAIC. As such, DMAIC

    is an integral part of a Six Sigma initiative.

    DMAIC also used to create a gated process for project

    control. The criteria for a particular phase are defined and the

    project is reviewed, and if the criteria are met then the next phase

    starts (Fig. 8) according to [1,16].

    As a summary of the application of the DMAIC technique, if you

    cannot defineyour process you cannot measureit. That means if

    you cannot express the data you are not able to utilize DMAIC in

    your development actions. Therefore, you cannot improve andsustain the quality [17, 18].

    DMAIC is an integral part of Six Sigma. It is systematic and

    fact based and provides a rigorous framework of results-oriented

    project management. The methodology may appear to be linear

    and explicitly defined, but it should be noted that the best results

    from DMAIC are achieved when the process is flexible, thus

    eliminating unproductive steps. An iterative approach may be

    necessary as well, especially when the team members are new to

    the tools and techniques.

    6. DFSS

    6.1 Definition

    DFSS (Design for Six Sigma)is a systematic and structured

    approach to new products or processes design that focuses on

    problem prevention.This is done with the aim of meeting or

    exceeding all the needs of the customer and the CTQ (critical to

    quality)output requirements when the product is first released.

    The major objective of DFSS is to design things right the first

    time.

    System consists from the set of tools, needs-gathering,

    engineering and statistical methods to be used during the

    products development. DFSS requires the rigorous use of tools

    and best practices to fulfil customer requirements and brings

    financial benefits by satisfying customer requirements [19].

    One fundamental characteristic of DFSS is the verification,

    which differentiates it from Six Sigma. The proponents of DFSS

    are promoting it as a holistic approachof re-engineering rather

    than a technique to complement Six Sigma.

    5.2. Application 6. DFSS

    6.1. Definition

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    Journal of Achievements in Materials and Manufacturing Engineering

    M. Sokovic, D. Pavletic, K. Kern Pipan

    Volume 43 Issue 1 November 2010

    6.2 Application

    The primary application of DFSS as a technique is in the

    design and development stage of a product, process or service.

    Designing new products or processes using DFSS approach does

    not replace current engineering methods, nor does it relieve anorganization of the need to peruse excellence in engineering and

    product development. It adds another dimension to product

    development. It helps in the process on inventing, developing,

    optimizing and transferring new technology into product design

    program. It also enables sub-sequent conceptual development,

    design, optimization and verification of new products prior to

    launch into their respective market [20, 21]. DFSS methodology

    delivers qualitative and quantitative results by managing critical

    parameters against the clear set of product requirements based on

    Voice of customer(VOC).

    Design for Six Sigma fits within the context of the key

    business process, namely the product development process;

    encompasses many tools and best practices that can be selectively

    deployed during the phases of a product development process.Specifically, DFSS integrates three major tactical elements to help

    attain the ubiquitous business goals of low cost, high quality and

    rapid cycle-time from product development [19].

    A clear and flexible product development process.

    A balanced portfolio of development and design tools and

    best practices.

    Disciplined use of project management methods.

    DFSS avoids counting failures and places the engineering

    team's focus on measuring real functions. The resulting

    fundamental model can be exercised, analyzed and verified

    statistically through Monte Carlo simulations and the sequential

    design of experiment (DoE).

    Defects and time-to-failure are not the main metrics of DFSS.

    DFSS uses continuous variables that are leading indicators of

    impending defects and failures to measure and optimize critical

    functional responses against assignable causes of variation in theproduction, delivery and use environment. We need to prevent the

    problems not wait until they occur and then react to them. The

    reason to using DFSS is ultimately financial. It generates

    shareholders value based on delivering customer value in the

    marketplace. DFSS helps fulfil voice of the businessby fulfilling

    voice of the customer.

    Most frequently reported methodologies for putting DFSS

    into practice are DMADV (Define, Measure, Analyze, Design

    and Verify) and IDOV (Identify, Design, Optimise and Validate).

    DMADV is often described as the next stage of DMAIC (Six

    Sigma) and thus may lead to a generic approach [1]. In order to

    emphasize the distinctive characteristic of DFSS we have adapted

    IDOV to show the basic steps of the process, Figure 9 [2].

    The proponents of DFSS believe that within the new fewyears, as experience grows, DFSS will be used in design houses

    with the same familiarity as ISO standards (ISO 9001, ISO 14001,

    ISO/TS 16949, and ISO OHSAS 18001).

    DFSS is a longer-term, resource-hungry process and it is

    expensive. Therefore, it should be deployed with care and on

    just a few vital projects, and specifically targeted towards thedevelopment of new products. Do not start a DFSS project

    without the customer, sales involvement, top-management

    commitment and a team, preferably one with Six Sigmatraining. DFSS is a powerful technique and its power should not

    be abused.

    Fig. 9.The relationship between DMADV (DFSS) and classical DMAIC (Six Sigma) - a new approach IDOV also is added [2]

    6.2. Application

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    7. Conclusions

    The methodology of implementing continuous quality

    improvement can be varied in different organization. Regardless

    of the methodology of the continuous-improvement programmes,

    every organization needs to use a proper combination andselection of quality tools, methodologies and techniques in their

    implementation process. It is very important that the tools,

    methodologies and techniques are properly selected according to

    the need and demands of the team and further applied correctly to

    the appropriate process and approach in organization

    The PDCA cycle (Deming's circle) is more than just a quality

    tool. The PDCA cycle is a fundamental concept of continuous-

    improvement processes embedded in the organizations culture. It

    is simple to understand and should be used by a large number of

    people in the company (also through-out standard ISO

    9001:2008). The most important aspect of PDCA lies in the act

    stage after the completion of a project when the cycle starts again

    for the further improvement.

    The methodology DMAIC (an integral part of Six Sigma) issystematic and fact based and provides a rigorous framework of

    results-oriented project management. It should be noted that the

    best results from DMAIC are achieved when the process is

    flexible, thus eliminating unproductive steps. An iterative

    approach may be necessary as well, especially when the team

    members are new to the tools and techniques.

    DFSS methodology is a systematic and disciplined approach

    to product or process design including all organization functions

    from the early beginning, with the objective to design things right

    from the first time. Voice of the customer (VOC), to gather

    customer requirements, and Quality Function Deployment (QFD)

    are tools to identify customer requirements, translate them into

    products technical design requirements and prioritize them

    according to weighted importance to meet customer basicrequirements. The methodology RADAR (an integral part of

    EFQM Excellence model) is strategic, systematic, fact-based

    framework which provides tool for evaluation of organizational

    results, approaches, deployment, assessment and review.

    Do not start a DFSS project or self-assessment project using

    excellence model and RADAR without the customer, sales

    involvement, top-management commitment and a team,

    preferably one with adequate training. Both DFSS and RADAR

    are complex, powerful techniques and their power should not be

    abused, and do not forget: both tools a longer-term and resource-

    demanding processes and should be deployed with care and

    implemented by appropriate planning, training, and monitored by

    project management.

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    7. Conclusions

    References

    http://www.journalamme.org/http://www.journalamme.org/http://www.journalamme.org/http://www.journalamme.org/http://www.journalamme.org/